Compliance Management for Manufacturing
Handle ISO standards, quality control, equipment maintenance, and workplace safety with digital tools built for production environments.
The Challenge
Manufacturing faces relentless pressure from quality standards, equipment maintenance schedules, workplace safety regulations, and production audits. Paper-based systems make it impossible to prove every machine was inspected before use, track which operators are qualified for which equipment, or demonstrate maintenance history when quality issues occur. Problems surface during ISO audits, customer inspections, HSE visits, or worse - after a quality escape reaches your customer or a workplace incident occurs.
How Assistant Manager Solves General Manufacturing Compliance
Each module is designed to address the specific challenges general manufacturing businesses face every day.
Checklist Management
Manufacturing needs machine-by-machine checklists that match equipment specifications and ISO requirements, with different frequencies for pre-shift, in-process, and end-of-shift inspections, plus quality checks aligned to control plans
The Problems
Why This Matters for General Manufacturing
- Pre-shift equipment checks are rushed or skipped during busy production periods, with operators ticking boxes without actually inspecting guards, emergency stops, and safety interlocks
A faulty safety guard or emergency stop goes undetected, leading to a workplace incident that triggers HSE investigation and potential prohibition notice
- Quality checks during production runs are inconsistent, with paper inspection forms showing checks were done but no verification of what was actually measured
Out-of-spec products go undetected until customer complaints arrive, and your paper inspection logs provide no defence during the quality investigation
The Solution
How Checklist Management Helps
Equipment-specific digital checklists with mandatory photo evidence, GPS verification that operators are at each machine, and timed completion requirements that prevent rushing
Every machine has documented evidence of thorough inspection, every quality check is verified with measurements, and supervisors are alerted immediately when checks are overdue or incomplete
Use Cases:
- • Pre-shift equipment safety checks with photo evidence of guards and interlocks
- • In-process quality inspection checklists aligned to control plans
- • Line clearance and changeover verification procedures
- • First-off inspection and dimensional verification
- • Environmental monitoring for temperature and humidity sensitive processes
- • End-of-shift equipment shutdown and housekeeping checks
- • 5S audit checklists for workspace organisation
Feature Screenshot
Checklist Management
Real-World Examples
Example 1: Pre-shift equipment checks are rushed or skipped during busy production periods, with operators ticking boxes without actually inspecting guards, emergency stops, and safety interlocks
Real Scenario
"A press brake emergency stop fails mid-shift. Investigation reveals the pre-shift check was completed in 2 minutes for equipment that requires 10 - the operator admits they didn't actually test the e-stop because production was behind schedule."
Example 2: Quality checks during production runs are inconsistent, with paper inspection forms showing checks were done but no verification of what was actually measured
Real Scenario
"A customer rejects a batch due to dimensional issues. Your inspection log shows in-process checks were completed, but operators can't remember what they actually measured - the customer's investigation reveals the measurements weren't physically possible with the documented inspection equipment."
Equipment Maintenance
Manufacturing facilities need maintenance systems that handle preventive schedules, breakdown response, and calibration tracking - with mobile access for maintenance teams and integration with production planning to minimise downtime
The Problems
Why This Matters for General Manufacturing
- Preventive maintenance schedules are tracked on spreadsheets or whiteboards, with no automatic alerts when maintenance is overdue and no visibility of equipment maintenance history
Equipment failures occur because preventive maintenance was missed, causing production stoppages, quality issues, and potential safety incidents
- Maintenance work is completed but documentation is poor or missing, with no record of what was done, parts replaced, or issues identified for future attention
When recurring faults occur or warranty claims are needed, there's no maintenance history to support troubleshooting or prove maintenance obligations were met
The Solution
How Equipment Maintenance Helps
Equipment-specific maintenance scheduling with automatic work order generation, mobile maintenance logging with parts tracking, and complete maintenance history for every asset
No maintenance is ever missed, every job is documented with photos and measurements, and you can instantly access complete maintenance history for any equipment
Use Cases:
- • Preventive maintenance scheduling with automatic work order creation
- • Breakdown maintenance logging with fault diagnosis documentation
- • Spare parts inventory and replacement tracking
- • Calibration schedules and certification management for metrology equipment
- • Equipment modification tracking with risk reassessment triggers
- • Maintenance KPI tracking including MTBF and MTTR
- • Maintenance history reports for ISO and customer audits
Feature Screenshot
Equipment Maintenance
Real-World Examples
Example 1: Preventive maintenance schedules are tracked on spreadsheets or whiteboards, with no automatic alerts when maintenance is overdue and no visibility of equipment maintenance history
Real Scenario
"A critical CNC machine breaks down during a high-priority customer order. Investigation reveals the scheduled hydraulic system maintenance was 3 months overdue - it was on the maintenance schedule but nobody checked. The breakdown costs £50,000 in lost production and late delivery penalties."
Example 2: Maintenance work is completed but documentation is poor or missing, with no record of what was done, parts replaced, or issues identified for future attention
Real Scenario
"A servo motor fails for the third time in 6 months. The supplier refuses warranty coverage because you can't provide documented evidence of proper preventive maintenance - the work was done but nothing was recorded in a way the supplier will accept."
Training & Development
Manufacturing needs equipment-specific training that covers setup procedures, quality requirements, and safety protocols - with robust assessment to prove operators are competent, not just 'trained'
The Problems
Why This Matters for General Manufacturing
- Equipment operator training is delivered verbally with paper sign-off sheets, and there's no way to verify operators actually understand the procedures or can demonstrate competency
When quality issues or safety incidents occur, operators make wrong decisions because their training was inadequate - and you can't prove what training was delivered
- Training certifications for forklift, overhead crane, and other equipment expire without notice, leaving the facility with unqualified operators using dangerous equipment
When HSE inspect or an incident occurs, they discover operators using equipment with expired certifications - creating serious regulatory and insurance exposure
The Solution
How Training & Development Helps
Equipment-specific training modules with video content, competency assessments, automatic certification tracking, and mandatory refresher scheduling
Every operator demonstrates competency before being authorised, certifications are tracked automatically, and you can prove exactly what training each person completed
Use Cases:
- • Equipment-specific operator training with competency assessment
- • Forklift and mobile equipment certification tracking
- • Overhead crane and lifting equipment operator qualification
- • Quality control and inspection technique training
- • New employee induction with completion verification
- • Annual refresher training scheduling and tracking
- • Supervisor and team leader development programmes
- • Contractor and temporary worker safety induction
Feature Screenshot
Training & Development
Real-World Examples
Example 1: Equipment operator training is delivered verbally with paper sign-off sheets, and there's no way to verify operators actually understand the procedures or can demonstrate competency
Real Scenario
"A new operator runs a batch out of specification because they didn't understand the setup procedure. Investigation reveals their 'training' was a 15-minute walkthrough with no assessment, documentation, or verification of competency - just a signature on a training matrix."
Example 2: Training certifications for forklift, overhead crane, and other equipment expire without notice, leaving the facility with unqualified operators using dangerous equipment
Real Scenario
"A workplace incident involves a forklift. HSE investigation discovers the operator's certification expired 8 months ago - it was on a training matrix but nobody tracked the renewal. You now face prohibition notices, enforcement action, and potential prosecution."
Risk Assessment
Manufacturing needs risk assessments for every significant hazard that align with HSE guidance and ISO 45001 requirements, plus flexible assessment tools for new processes and non-standard operations
The Problems
Why This Matters for General Manufacturing
- Generic equipment risk assessments were created years ago and never updated when operating procedures changed or new hazards were identified
Risk assessments don't reflect actual hazards, providing no real protection for workers and no defence when HSE investigate an incident
- New processes, equipment installations, and temporary setups have no specific risk assessments because production can't wait for paperwork
When an incident occurs on new equipment or during a non-standard operation, there's no documented risk assessment to demonstrate hazards were considered
The Solution
How Risk Assessment Helps
Equipment-specific risk assessments with AI-suggested control measures, modification tracking, and automatic review reminders linked to operational changes
Every machine and process has a current, specific risk assessment that reflects actual operations, with clear audit trails showing how risks have been managed
Use Cases:
- • Equipment-specific risk assessments for all production machinery
- • Process hazard analysis for manufacturing operations
- • Chemical handling and COSHH assessment integration
- • Confined space entry risk assessments
- • Hot work and maintenance activity assessments
- • Modification tracking with risk reassessment triggers
- • Contractor and visitor safety assessments
Feature Screenshot
Risk Assessment
Real-World Examples
Example 1: Generic equipment risk assessments were created years ago and never updated when operating procedures changed or new hazards were identified
Real Scenario
"A machine is modified to increase throughput. A worker is injured in the new operation. HSE find the risk assessment still describes the original setup - nobody updated it when the operation changed, despite the modification introducing new pinch points."
Example 2: New processes, equipment installations, and temporary setups have no specific risk assessments because production can't wait for paperwork
Real Scenario
"A temporary production line is set up to handle a rush order. A contractor is injured working on unfamiliar equipment. There's no risk assessment for the temporary setup, no documentation of additional hazards, and no proof that safety was considered before starting production."
Accident & Incident Records
Manufacturing needs incident documentation that meets HSE expectations, with trend analysis to identify recurring issues across equipment and processes, plus RIDDOR determination and reporting workflow
The Problems
Why This Matters for General Manufacturing
- Workplace incidents are documented inconsistently, with some logged in the first aid book, some reported verbally to supervisors, and many near-misses going unrecorded entirely
When HSE investigate or insurance claims arrive, incident records are incomplete, contradictory, or missing entirely, making defence impossible
- Near-misses and equipment issues are not systematically recorded, so patterns that could predict serious incidents are never identified
The same fault occurs repeatedly until it finally causes an injury, at which point investigation reveals the problem was known but never addressed
The Solution
How Accident & Incident Records Helps
Mobile incident reporting with equipment-specific forms, photo evidence, automatic RIDDOR assessment, and trend analysis across all operations
Every incident is documented immediately with complete evidence, patterns are identified before they cause serious harm, and HSE investigations find comprehensive records
Use Cases:
- • Workplace incident documentation with witness statements
- • Injury reporting with first aid treatment records
- • Near-miss and hazard observation logging
- • Equipment fault and malfunction reporting
- • RIDDOR determination and reporting for serious incidents
- • Trend analysis by equipment, process, and incident type
- • Investigation workflow with root cause analysis
- • Corrective action tracking and effectiveness verification
Feature Screenshot
Accident & Incident Records
Real-World Examples
Example 1: Workplace incidents are documented inconsistently, with some logged in the first aid book, some reported verbally to supervisors, and many near-misses going unrecorded entirely
Real Scenario
"A worker claims they reported a machine fault before an incident. The supervisor has no record of the conversation. Without documentation, it becomes the worker's word against the supervisor's - and the company loses the claim."
Example 2: Near-misses and equipment issues are not systematically recorded, so patterns that could predict serious incidents are never identified
Real Scenario
"A machine guard sensor fails intermittently three times in one month. Operators manually reset it each time without formal reporting. On the fourth occurrence, a worker reaches into the machine and is seriously injured. Investigation reveals the known intermittent fault was never documented or investigated."
COSHH Assessments
Manufacturing uses diverse chemicals from production processes to maintenance and cleaning, often in multiple locations across the facility - COSHH management needs mobile access to safety information and integration with procurement to catch new chemicals before they're used
The Problems
Why This Matters for General Manufacturing
- Production chemicals, coolants, solvents, and cleaning products are used without current COSHH assessments, with Safety Data Sheets buried in filing cabinets or outdated
Staff suffer chemical burns, respiratory issues, or dermatitis from improper handling, and HSE find no COSHH assessments during inspections
- New chemicals arrive on site and are put into use before COSHH assessment is completed because production can't wait for paperwork
Operators use chemicals without proper PPE, ventilation, or handling procedures, exposing themselves to harm with no documented risk assessment
The Solution
How COSHH Assessments Helps
COSHH assessment management with chemical inventory tracking, mobile SDS access, AI-powered product identification from photos, and integration with training records
Every chemical has a current COSHH assessment before use, staff can access safety information instantly on their phone, and chemical handling training is documented
Use Cases:
- • Production chemical COSHH assessments for cutting fluids, solvents, and process chemicals
- • Maintenance chemical and lubricant management
- • Cleaning chemical assessments for housekeeping
- • Welding fume and process dust assessments
- • Chemical procurement approval workflow
- • Staff training records for chemical handling
- • Mobile SDS access for emergency response
- • Spill response procedure documentation
Feature Screenshot
COSHH Assessments
Real-World Examples
Example 1: Production chemicals, coolants, solvents, and cleaning products are used without current COSHH assessments, with Safety Data Sheets buried in filing cabinets or outdated
Real Scenario
"A machine operator develops severe dermatitis from cutting fluid exposure. Investigation reveals the COSHH assessment is 5 years old and based on a different product - the supplier changed the formulation but nobody updated the assessment. HSE issue an improvement notice."
Example 2: New chemicals arrive on site and are put into use before COSHH assessment is completed because production can't wait for paperwork
Real Scenario
"A new cleaning solvent arrives for a special project. It's used immediately because the job is urgent. Three workers report headaches and nausea - investigation reveals the product releases harmful vapours and requires local exhaust ventilation that wasn't in place."
Quality Management
Manufacturing quality management needs to connect shop floor issues with corrective actions and customer communications - the system must prevent issues from being forgotten and prove to auditors that problems are systematically resolved
The Problems
Why This Matters for General Manufacturing
- Non-conformances are documented on paper forms that get lost, take days to reach quality management, and have no automatic follow-up on corrective actions
The same quality issues recur because corrective actions are never completed or verified, and customer audits find non-conformances that were supposedly closed months ago
- Customer complaints arrive via email, phone, or returns paperwork, with no systematic process to log, investigate, and track resolution through to customer satisfaction
Complaints are handled inconsistently, response times are slow, and customers escalate because they receive no updates - damaging relationships and losing future business
The Solution
How Quality Management Helps
Mobile non-conformance reporting with automatic workflow routing, corrective action tracking with evidence verification, and integrated customer complaint management
Every quality issue is captured immediately, corrective actions are tracked to verified completion, and customers receive timely updates on complaint resolution
Use Cases:
- • Non-conformance reporting with automatic notification to quality team
- • Root cause analysis workflow with 8D methodology support
- • Corrective action tracking with evidence verification
- • Customer complaint management with response tracking
- • Supplier quality issue documentation and escalation
- • Internal audit non-conformance management
- • Management review KPI and trend reporting
Feature Screenshot
Quality Management
Real-World Examples
Example 1: Non-conformances are documented on paper forms that get lost, take days to reach quality management, and have no automatic follow-up on corrective actions
Real Scenario
"A customer audit reviews closed non-conformances from the past year. They select five at random to verify - three have no evidence of corrective action completion, and two supposedly fixed issues are found to still be occurring on the production floor."
Example 2: Customer complaints arrive via email, phone, or returns paperwork, with no systematic process to log, investigate, and track resolution through to customer satisfaction
Real Scenario
"A key customer sends a formal complaint about a quality issue. The email goes to a sales person who forwards it to production. Three weeks later the customer escalates to your MD because they've received no response - nobody was tracking the complaint or owned the resolution."
Permit to Work
Manufacturing facilities need permit systems for hot work, confined spaces, electrical isolation, and working at height - with mobile access for contractors and integration with equipment isolation procedures
The Problems
Why This Matters for General Manufacturing
- Hot work permits are issued on paper forms that are easily lost, with no verification that required precautions are actually in place before work starts
Contractors start hot work without proper fire watch, equipment isolation, or area clearance - creating serious fire risk and regulatory exposure
- Confined space entry permits don't track atmospheric testing results, rescue equipment verification, or ongoing monitoring during the work
Workers enter confined spaces with inadequate controls, atmospheric monitoring isn't maintained, and rescue equipment may not be available if needed
The Solution
How Permit to Work Helps
Digital permit to work with mandatory photo evidence of precautions, electronic sign-off workflow, atmospheric testing logging, and automatic permit expiry alerts
Every high-risk job has verified controls in place before work starts, atmospheric testing is documented in real-time, and expired permits automatically lock out work
Use Cases:
- • Hot work permits with fire watch and clearance verification
- • Confined space entry permits with atmospheric testing logs
- • Electrical isolation permits with LOTO verification
- • Working at height permits with fall protection checks
- • Equipment isolation permits with energy verification
- • Excavation permits for site work
- • Contractor permit management with induction verification
Feature Screenshot
Permit to Work
Real-World Examples
Example 1: Hot work permits are issued on paper forms that are easily lost, with no verification that required precautions are actually in place before work starts
Real Scenario
"A contractor starts welding in a production area. Within minutes a fire starts in combustible materials that weren't cleared from the work area. Investigation reveals the hot work permit showed all precautions were in place, but nobody actually verified them - the form was just signed."
Example 2: Confined space entry permits don't track atmospheric testing results, rescue equipment verification, or ongoing monitoring during the work
Real Scenario
"A maintenance worker collapses in a tank. Rescue is delayed because the rescue harness mentioned on the permit isn't actually available - it was on the permit form but nobody verified. The injury is more serious because of the delayed rescue."
Results General Manufacturing Businesses Achieve
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